J.I. Case Service Manual 780CK Tractor, Loader, & Backhoe Volume 1 of 3 Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF J.I. CASE OR IT S SUCCESSORS. J.I. CASE AND IT S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL. TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS. CA-S-780CK TLB
780 CK LOADER BACKHOE TABLE OF CONTENTS SERI ES/SECTION SECTION NO. FORM NO. 10 SERIES - GENERAL Maintenance and Lubrication... 13" General Engine Specifications... 1010 Detailed Engine Specifications... 1023 20 SERIES - ENGINE General Engine Service and Removal... 21 Engine Air Cleaner... 24 Air Cleaner rnstalration, Turbocharged Engine... 24, Sup. 1 Engine Diagnosis... "... 2001 Engine Tuneup... 2002 Cylinder Head, Valve Train, and Camshaft... 2015 Cylinder Block, Sleeves, Pistons and Rods... 2025 Crankshaft, Main Bearings, Flywheel and Oil Seal Replacement... 2035 Lubrication System... 2047 Cooling System... 2055 Turbocharger Failure Analysis... 2565 30 SERIES - FUEL SYSTEM Electric Fuel Pump... 34 Fuel Tank and Fuel Lines... 36 Fuel System and Filters... 3010 Robert Bosch Fuel Injection Pump... 3012 Roosa Master Fuel Injectors... 3013 40 SERIES - HYDRAULICS Hydraulic System Flowmeter Tests and Pressure Checks (All Machines)... 40 Loader/Backhoe Hydraulic System....41 Loader Hydraulic Diagram After SN 5500550, Backhoe Hydraulic ' Diagram and Installations, Loader Control Valve, Dipper Extension Cylinder....41, Sup. 1 Backhoe Control Valve... 44 Backhoe Basic Hydraulic Installation and Control Levers.44, Sup. 1 Hydra-Guide... 47 50 SERIES - STEERING Steering Hydraulic System... 51 Front Axle... 58 60 SERIES - POWER TRAIN Clark Transmission Maintenance and Service Manual, HR28000 Series, 2 Speed... '.'.... Clark Transmission Maintenance and Service Manual Supplement, To Be Used in Conjunction with the HR28000 Series, 2 Speed Maintenance and Service Manual.... 9-80675 9-78646 9-76365 9-76379 9-76166 9-76176 9-76187 9-78667 9-76337 9-78235 9-75297 9-74937 9-74959 SM HR282 SMS 282,:.:- CASE CORPORATION CE Div. 9-71439.,PRINTED IN, U.S.A.
SERIES/SECTION SECTION NO. FORM. NO. 60 SERIES - POWER TRAIN (CONTO.) General Transmission Service and Removal... 63 Differential, Planetaries and Drive Shaft... 67 Differential and Planetaries (Tractor SN 5500354 and After, Except 5500426 thru 5500439)... 67, Sup. 1 70 SERIES - BRAKES Brake System Diagram/Operation... 71- Brake System... ~... 72 80 SERIES - ELECTRICAL Electrical System... 82 Wiring Diagram, Trouble Shooting the Starting and Charging Circuits, A15485 and R26136 Starters, Ether Injector Starting Aid... 82, Sup. 1 90 SERIES - MOUNTED EQUIPMENT Loader... 92 Loader Exploded Views, Return-To-Dig, Anti-Rollback, SN 5500550 and After _... 92, Sup. 1 Backhoe... 93 Boom Lock, Dipper Extension, Hydraulic Installations with SN 5500550 and After, Backhoe Controls with SN 5500166 and After and SN 5500155 and 5500162... 93, Sup. 1 Rollover Protective Structure... 99
Figure 3 - Exploded View of Backhoe Throttle Linkage Section 21 9
INSTALLATION OF CONVERTER DRIVE RINO ON ENOINE FLYWHEEL ENGINE FLYWHEEl 3/8" NC X 1-1/2" BOLT 0/ 702162 Figure 4 - Drive Ring Installation 1. Install drive ring on :flywheel and 10rque bolts 20-25 foot pounds above the torque required 10 run bolts in place. When 10rquing drive ring bolts do not tighten consecutive bolts; tighten opposites. CAUTION: Bolts and washers supplied with the drive ring must be used. The use of washers with a smaller 0.0. than those supplied will result in damage to the drive ring. 2. Lock wire bolts with continuous wire so it does not interfere with gear teeth. 10 Section 21
The air cleaner filter element must be serviced when the red band on the air cleaner restriction indicator remains in full view. In addition to filter service the dust cup should be cleaned daily or more often as conditions warrant. Filter Element Service The preferred method of cleaning the filter is by washing. Washing the filter results in restoring the filter to an almost new condition and longer intervals between servicing. It is recommended that a spare filter be available to allow sufficient drying time for the serviced filter and to reduce machine downtime. Wash the filter in Case Filter Element Cleaner (Part No. A40910) according to instructions on container. Rinse thoroug~y. Do not use water pressure over 40 psi at nozzle. Set filter aside to dry. Do not use compressed air to dry. Use of compressed air to clean the filter is permissible but not recommended as it does not remove carbon and soot. When using compressed air. u~e no more than 30 psi at nozzle. Inspect filter after it is clean and dry. Place a light inside filter and inspect for holes. tears, and dented or bent metal -...:::-.. -.-. Figure 2 - Inspecting The Element covering. If metal covering is dented or bent, inspect filter paper for holes or rub spots in that area. If holes or rub sports are noted, discard filter and install new filter element. NOTE: Inspect new filter element for defects in the same manner. Do not accept a defective filter. The filter must be replaced after it has been cleaned six times or once a year. whichever occurs first. Section 24 3
2002-15 STEP 43 (CLAMP TYPE INJECTOR) STEP 45 (CLAMP TYPE INJECTOR) ClAMP ASSEM.LY~ SPACER~ INSET A ALWAYS TURN TOOL CLOCKWISE. COUNTER CLOCKWISE ROTATION DULLS TOOL. BLOW OUT WITH COMPRESSED AIR. STEP 44 (SCReW-IN TYPE INJECTOR) BORE CLEANING TOOL NUDAY CO. PIN 6062 14615 WYOMING AVE. DETROIT. MICHIGAN 48238 (PART OF KIT 2205) INSTALL BACHARACH 70-314 (0-558) COMPRES SION GAUGE ADAPTER. SECURE WITH AN ORIGI NAL INJECTOR CLAMP ASSEMBLY AND SPACER. STEP 46 (CLAMP TYPE INJECTOR) ~'t---..!..l..w;c:~,\ E CLEAN CYLINDER HEAD INJECTOR BORE USING BORE CLEANING TOOL 6062. CD-504 COMPRESSION GAUGE CONNECT CASE NO. CD-504COMPRESSION GAUGE TO ADAPTER. NOTE: TAKE SEVERAL COMPRESSION READINGS ON EACH CYLINDER USING VENT VALVE BUTTON TO RELIEVE GAUGE PRESSURE. SEE CHART ON NEXT PAGE.
2002-16 STEP 47 (SCREW-IN TYPE INJECTOR) STEP 48 NEW FUEL INJECTOR GASKET ~l NOTE: WHEN CHECKING COMPRESSION USING THE CRANKING METHOD. START AT NO. 1 CYLINDER AND CONTINUE DOWN THE LINE (NO.2. 3. 4 ETC). THEN. RECHECK NO. 1 CYLINDER AFTER COM PLETING THE LAST CYLINDER SINCE COMPRES SION MAY VARY. DUE TO BATTERY RUN-DOWN. COMPRESSION GAUGE ADAPTER NUDAY CO. PIN 6050 14615 WYOMING AVE. DETROIT. MICHIGAN. 48238 (PART OF KIT 2205) I.'-, \\ \ \ CD-504 COMPRESSION GAUGE r~ "" STEP 49 IT IS VERY IMPORTANT THAT ALL CYLINDER PRESSURES BE APPROXIMATELY THE SAME. SEE CHART FOR ALLOWABLE COMPRESSION PRESSURE VARIATION. IF COMPRESSION IS GREATER THAN NORMAL. CARBON DEPOSITS ARE INDICATED. IF READ ING IS BELOW NORMAL. LEAKING VALVES OR EXCESSIVE RING CLEARANCE IS INDICATED. ), ~:::=- \\ \ ADAPTER \ ~ \\'-l't't~-ltorque 35 TO 45 FT. LBS. I./""~iA\"--" J, 'I,\ INSTALL GAUGE ADAPTER WITH A NEW FUEL IN JECTOR GASKET. IN CYLINDER HEAD. TORQUE ADAPTER 35 TO 45 FT. LBS. CONNECT CASE NO. CD-504COMPRESSION GAUGE TO ADAPTER. NOTE: TAKE SEVERAL COMPRESSION READINGS ON EACH CYLINDER USING VENT VALVE BUTTON TO RELIEVE GAUGE PRESSURE. ENGINE SPEED NORMAL COMPRESSION PRESSURE ALLOWABLE VARIATION BETWEEN CYLINDERS CRANKING RUNNING APPROXIMATELY 200 RPM UNTIL COMPRESSION GAUGE STABILIZES 800 RPM 400 PSI* 25 PSI 480 PSI* 20 PSI NOTE: A 4% REDUCTION IN PSI MUST BE ALLOWED FOR EVERY 1000 FT. ABOVE SEA LEVEL.
2015-20 STEP 42 STEP 451-- O FIRE RING REMOVE 'the SPRING COMPRESSOR AND TAP VALVE STEM TO SEAT KEEPERS. CYLINDER HEAD GASKET WITH FIRE RINGS PART OF GASKET. STEP 43 INSTALL INTAKE AND EXHAUST VALVES, FOLLOWING THE PRECEDING PROCED URE. STEP 46 STEP 44 PLACE CYLINDER HEAD ON ENGINE BLOCK AND INSTALL CYLINDER HEAD BOLTS, FINGER TIGHT ONLY. AND WASHERS. NOTE: BEFORE INSTALLING CYLINDER HEADS ON BLOCK, CLEAN THE INJECTOR BORES US ING A43277 REAMER.
2015-21 STEP 47 STEP 50 Insert dowel pin removal tong A40952. STEP 48 ~. Install new intake manifold gaskets. STEP 51 Remove dowel pins and install remaining cylinder head bolts and washers. STEP 49 0) ~ Install intake manifold and torque retaining nuts as follows: Cast iron manifold (std. hex. nuts) - 25 to 30 ft. Ibs. Aluminum manifold (heavy hex. nuts) - 35 to 42 ft. Ibs. STEP 52 Install new water manifold gaskets.
2025-5 STEP 5 _... c>... 7t12 " g -.../c> )Y1 CHECK THE PISTON SLEEVES FOR A RIDGE AT THE TOP OF THE RING TRAVEL IF A RIDGE IS PRESENT. IT MUST BE REMOVED BEFORE THE PISTONS CAN. BE REMOVED. STEP 6 ~~ IJI CHECK THE PISTON RODS AND CAPS TO SEE IF THEY ARE NUMBERED AS TO THEIR LOCATION IN THE ENGINE. IF NOT. THEY MUST BE NUM- BERED FOR REINSTALLATION IN THEIR ORIGIN AL LOCATION. STEP 8 REMOVE THE PISTON ROD CAPS. STEP 9 USE A RIDGE REAMER TO REMOVE THE RIDGE OR DAMAGE TO THE PISTON RINGS AND LANDS WILL RESULT. /, I PUSH THE PISTON ROD UP THROUGH THE EN GINE BLOCK.